Apparatuses and Methods for Bonding Substrates

ABSTRACT

An apparatus includes a drum that rotates about an axis and rotating an anvil roll that rotates about an axis of rotation. The drum includes a fluid nozzle and a press member, the press member having an outer surface. The anvil roll includes a compliant outer circumferential surface. First and second substrates are advanced in a machine direction onto the drum. The fluid nozzle moves radially outward and a jet of heated fluid may be directed onto the substrates. The fluid nozzle retracts radially inward and the press member may be shifted radially outward. The substrates may be compressed between the press member and the anvil roll such that the press member deforms the compliant outer circumferential surface of the anvil roll.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/038,812 filed on Sep. 27, 2013, which is incorporated herein byreference.

FIELD

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for bondingsubstrates together during the manufacture of absorbent articles.

BACKGROUND

Along an assembly line, various types of articles, such as diapers andother absorbent articles, may be assembled by adding components toand/or otherwise modifying an advancing, continuous web of material. Insome processes, advancing webs of material are combined with otheradvancing webs of material. In other processes, individual componentscreated from advancing webs of material are combined with advancing websof material, which in turn, are then combined with other advancing websof material. In some cases, individual components created from advancingweb or webs are combined with other individual components created fromother advancing web or webs. Webs of material and component parts usedto manufacture diapers may include: backsheets, topsheets, leg cuffs,waist bands, absorbent core components, front and/or back ears,fastening components, and various types of elastic webs and componentssuch as leg elastics, barrier leg cuff elastics, stretch side panels,and waist elastics. Once the desired component parts are assembled, theadvancing web(s) and component parts are subjected to a final knife cutto separate the web(s) into discrete diapers or other absorbentarticles.

In some converting configurations, discrete chassis spaced apart fromeach other are advanced in a machine direction and are arranged with alongitudinal axis parallel with the cross direction. Opposing waistregions of discrete chassis are then connected with continuous lengthsof elastically extendable front and back belt webs advancing in themachine direction. While connected with the chassis, the front and backbelt webs are maintained in a fully stretched condition along themachine direction, forming a continuous length of absorbent articles.The continuous length of absorbent articles may then be folded in across direction. During the folding process in some convertingconfigurations, one of the front and back belt webs is folded into afacing relationship with the opposing belt. The front and back belts maythen be bonded together to create the side seams on diapers.

Portions of the front and back belt may be partially melted andcompressed together to create side seams. The seaming process mayinclude advancing the front and back belts through a nip formed betweena rotating anvil roll and a rotating compression tool. As the front andback belts advance through the nip, the compression tool may compressthe front and back belts against the anvil roll. The anvil and thecompression tool may be made of a rigid material. In some processes, theamount of time that the front and back belts are compressed may affectthe strength and quality of the seam. In particular, increasedcompression time may increase the quality and strength of the seam.However, in a high speed manufacturing process utilizing a rigid anvilroll and a rigid compression tool, the anvil roll and the compressiontool may be spaced apart so as to prevent interference between the anvilroll and the compression tool. As a result, the compression time may benearly instantaneous as the front and back belts pass through the nipformed between the anvil roll and the compression tool.

In some processes, compressing the advancing substrates in a directionthat is non-tangential to both the outer surface of the compression tooland the outer circumferential surface of the anvil roll may improve theseam quality and strength. However, in a process utilizing a rigidcompression tool and a rigid anvil roll spaced apart so as to preventinterference, the substrate may be compressed in a direction that istangential to both the outer surface of the anvil roll and of thecompression tool.

Thus, it would be beneficial to provide an apparatus and a method forincreasing the compression time for bonding substrates together to forma side seam in a high speed manufacturing process. In addition, it wouldbe beneficial to provide a process and apparatus for compressingsubstrates in a direction that is non-tangential to the outer surface ofthe compression tool and the outer circumferential surface of the anvil.

SUMMARY

Aspects of the present disclosure include an apparatus for bonding firstand second substrates together. The first and second substrates may havea combined, uncompressed caliper. The apparatus may include a drumincluding an outer circumferential surface and a drum aperture in theouter circumferential surface. The drum may be adapted to rotate aboutan axis of rotation. The apparatus may also include a fluid nozzlemoveably connected to the drum, located radially inward relative to thedrum aperture, and adapted to direct a fluid radially outward throughthe drum aperture. The apparatus may also include an anvil roll and apress member. The anvil roll may include an outer circumferentialsurface located adjacent the drum. The anvil roll and the drum maydefine a nip therebetween. The anvil roll may be adapted to rotate aboutan axis of rotation. The anvil roll may include a compliant sleeve thatdefines the outer circumferential surface of the anvil roll. The outercircumferential surface of the anvil roll may be deformable toward theaxis of rotation of the anvil roll. The press member may be moveablyconnected to the drum, located radially inward relative to the drumaperture, and adapted to extend through the drum aperture.

Aspects of the present disclosure include an apparatus bonding first andsecond substrates together. The first and second substrates may have acombined, uncompressed caliper. The apparatus may include a drum havingan outer circumferential surface and a drum aperture in the outercircumferential surface. The drum may be adapted to rotate about an axisof rotation. The apparatus may also include a fluid nozzle. The fluidnozzle may be moveably connected to the drum, located radially inwardrelative to the drum aperture, and adapted to direct a fluid radiallyoutward through the drum aperture. The apparatus may also include ananvil roll and a press member. The anvil roll may include an outercircumferential surface located adjacent the drum so as to define a nipbetween the anvil roll and the drum. The anvil roll may be adapted torotate about an axis of rotation. The press member may be moveablyconnected to the drum, located radially inward relative to the drumaperture, and adapted to extend through the drum aperture.

Aspects of the present disclosure include an apparatus for bonding firstand second substrates together. The first and second substrates may havea combined, uncompressed caliper. The apparatus may include a drumhaving an outer circumferential surface and a drum aperture in the outercircumferential surface. The drum may be adapted to rotate about an axisof rotation. The apparatus may also include a fluid nozzle and a pressmember. The fluid nozzle may be moveably connected to the drum, locatedradially inward relative to the drum aperture, and adapted to direct afluid radially outward through the drum aperture. The press member maybe moveably connected to the drum, located radially inward relative tothe drum aperture, and adapted to extend through the drum aperture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a diaper pant.

FIG. 2A is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 2B is a partially cut away plan view of a second configuration of adiaper pant.

FIG. 3A is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pants of FIGS. 2A and 2Btaken along line 3B-3B.

FIG. 4 is a schematic side view of a converting apparatus adapted tomanufacture pre-fastened, pant diapers.

FIG. 5A is a view of a continuous length of chassis assemblies from FIG.4 taken along line A-A.

FIG. 5B1 is a view of a discrete chassis from FIG. 4 taken along lineB1-B1.

FIG. 5B2 is a view of a discrete chassis from FIG. 4 taken along lineB2-B2.

FIG. 5C is a view of continuous lengths of advancing front and back sidepanel material from FIG. 4 taken along line C-C.

FIG. 5D is a view of multiple discrete chassis spaced from each otheralong the machine direction MD and connected with each other by thefront and back side panel material from FIG. 4 taken along line D-D.

FIG. 5E is a view of folded multiple discrete chassis with the front andback side panel material in a facing relationship from FIG. 4 takenalong line E-E.

FIG. 5F is a view of two discrete absorbent articles advancing themachine direction MD from FIG. 4 taken along line F-F.

FIG. 5G is a view of an overlap area of the first and second substratesfrom FIG. 5D taken along line 5G-5G.

FIG. 6A is a schematic side view of a bonder apparatus adapted to seampre-fastened pant diapers.

FIG. 6A1 is a detailed, schematic side view of the bonder apparatus ofFIG. 6A.

FIG. 6B is an elevation view of the seamer station of FIG. 6A.

FIG. 6B1 is a detailed elevation view of the seamer station of FIG. 6B.

FIG. 7 is a detailed, exploded view of a seaming station.

FIG. 8 is an elevation view of a seaming station.

FIG. 9 is a partial, side elevation view of a press member and an anvilroll that is configured to deform first and second substrate layers in az-direction.

FIG. 10 is a perspective view of a seaming station in a firstconfiguration.

FIG. 11 is a schematic side view of a bonder apparatus adapted to seampre-fastened diapers.

FIG. 12 is a perspective view of a seaming station in the secondconfiguration.

FIG. 13 is a partial, side elevation view of a press member and an anvilroll.

FIG. 14 is a partial, side elevation view of a press member and an anvilroll.

FIG. 15 is a partial, side elevation view of a press member and an anvilroll.

FIGS. 16-19 are perspective side views of a bonder apparatus adapted toseam pre-fastened pant diapers.

DETAILED DESCRIPTION

This application claims the benefit of U.S. Provisional Application Ser.No. 61/717,268, filed Oct. 23, 2012, the entirety of which isincorporated by reference herein.

The following definitions may be useful in understanding the presentdisclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. “Diaper” isused herein to refer to an absorbent article generally worn by infantsand incontinent persons about the lower torso. The term “disposable” isused herein to describe absorbent articles which generally are notintended to be laundered or otherwise restored or reused as an absorbentarticle (e.g., they are intended to be discarded after a single use andmay also be configured to be recycled, composted or otherwise disposedof in an environmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers herein to a materialthat upon application of a force to its relaxed, initial length canstretch or elongate to an elongated length more than 10% greater thanits initial length and will substantially recover back to about itsinitial length upon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

“Longitudinal” means a direction running substantially perpendicularfrom a waist edge to a longitudinally opposing waist edge of anabsorbent article when the article is in a flat out, uncontracted state,or from a waist edge to the bottom of the crotch, i.e. the fold line, ina bi-folded article. Directions within 45 degrees of the longitudinaldirection are considered to be “longitudinal.” “Lateral” refers to adirection running from a longitudinally extending side edge to alaterally opposing longitudinally extending side edge of an article andgenerally at a right angle to the longitudinal direction. Directionswithin 45 degrees of the lateral direction are considered to be“lateral.”

“Radial” means a direction running from the center of a drum toward anouter circumferential surface.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layered materials. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is not parallel with, and usually perpendicular to, the machinedirection.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed byvarious techniques including, but not limited to, joining togetherportions of the article using any refastenable and/or permanent closuremember (e.g., seams, heat bonds, pressure welds, adhesives, cohesivebonds, mechanical fasteners, etc.). A pant can be preformed anywherealong the circumference of the article in the waist region (e.g., sidefastened or seamed, front waist fastened or seamed, rear waist fastenedor seamed).

“Pre-fastened” refers herein to pant diapers manufactured and providedto consumers in a configuration wherein the front waist region and theback waist region are fastened or connected to each other as packaged,prior to being applied to the wearer. As such pant diapers may have acontinuous perimeter waist opening and continuous perimeter leg openingsdesigned for infant or adult wearers. As discussed in more detail below,a diaper pant can be preformed by various techniques including, but notlimited to, joining together portions of the diaper using refastenableand/or permanent closure members (e.g., seams, heat bonds, pressurewelds, adhesives, cohesive bonds, mechanical fasteners, etc.). Inaddition, pant diapers can be preformed anywhere along the circumferenceof the waist region (e.g., side fastened or connected, front waistfastened or connected, rear waist fastened or connected).

“Compliant” refers herein to any material with a durometer between 20and 100 as measured according to ASTM International Designation: D2240for Type A durometers.

The present disclosure relates to methods and apparatuses for bondingsubstrates together. As discussed in more detail below, the bonderapparatus may include a drum and an anvil roll adjacent the drum. Theanvil roll and the drum may each include an outer circumferentialsurface. The drum may also include an aperture in the outercircumferential surface and one or more seaming stations locatedradially inward from the outer circumferential surface of the drum. Theouter circumferential surface of the anvil roll may comprise a compliantmaterial. As discussed in more detail below, the seaming station mayinclude a fluid nozzle operatively connected with a press member. Duringthe bonding operation, the drum is rotated about an axis of rotation anda first substrate layer advances in a machine direction onto the outercircumferential surface of the drum. A second substrate layer is alsoadvanced in the machine direction, wherein the first substrate layer isbetween the second substrate layer and the drum. A fluid is heated to atemperature sufficient to at least partially melt the substrates. As thedrum rotates, the fluid nozzle moves radially outward toward theaperture in the outer circumferential surface of the drum. The fluidnozzle directs a jet of the heated fluid through the aperture and ontoan overlap area of the first and second substrate layers, whichpartially melts the overlap area. As the drum continues to rotate, thefluid nozzle retracts radially inward from the aperture, and the pressmember moves radially outward through the aperture.

The partially melted overlap area is then advanced through a nip formedbetween the press member and the anvil roll, thereby compressing theoverlap area of the first and second substrates between the press memberand the anvil roll. The press member may press the overlap area againstthe anvil roll such that the outer circumferential surface of the anvilroll is deformed radially inward toward the axis of rotation of theanvil roll. The press member may deform the outer circumferentialsurface of the anvil roll a radial thickness that is at least 25% of thecaliper of the uncompressed, unmelted first and second substrateslayers. Concurrently, the first and second substrates may be deformed ina direction that is non-tangential to the outer circumferential surfaceof the anvil roll and the outer surface of the press member. As aresult, a discrete bond regions or seams are formed between the firstand second substrates. Next, the drum continues to rotate and the pressmember retracts radially inward from the aperture.

It is to be appreciated that although the bonding methods andapparatuses herein may be configured to bond various types ofsubstrates, the methods and apparatuses herein are discussed below inthe context of manufacturing absorbent articles. In particular, themethods and apparatuses are discussed in the context of bonding beltsubstrates together to form side seams on advancing, continuous lengthsof absorbent articles during production. As discussed below, anadvancing continuous length of absorbent articles may include aplurality of chassis connected with a continuous first belt substrateand a continuous second belt substrate. The continuous first and secondbelt substrates may be separated from each other along a cross directionwhile advancing along a machine direction. Each chassis may extend inthe cross direction and may include opposing first and second endregions separated by a central region, wherein the first end regions areconnected with first belt substrate and the second end regions areconnected with the second belt substrate. The chassis may also be spacedfrom each other along the machine direction.

A folding apparatus operates to fold the chassis around the folding axisalong the central regions and to bring the second belt substrate andsecond end region of the chassis into a facing relationship with thefirst belt substrate and first end region of the chassis. In someexemplary configurations, the first belt substrate, second beltsubstrate, folded chassis advance in the machine direction onto theouter circumferential surface of a rotating drum such as describedabove. As the drum rotates, a fluid nozzle moves radially outward towardan aperture in the outer circumferential surface of the drum. The fluidnozzle directs a jet of the heated fluid through the aperture and ontoan overlap area of the first and second belt substrates, which partiallymelts the overlap area. As the drum continues to rotate, the fluidnozzle retracts radially inward from the aperture, and the press membermoves radially outward through the aperture. The partially meltedoverlap area is then compressed between the press member and an anvilroll, creating discrete bond sites or seams between the first and secondbelt substrates. The drum continues to rotate and the press memberretracts radially inward from the aperture, and the continuous length offirst and second belt substrates are advanced from the drum to a kniferoll. The bonded regions are cut by the knife roll along the crossdirection to create a first side seam on an absorbent article and asecond side seam on a subsequently advancing absorbent article.

While the following discussion relates to bonding one or more substratelayers, it is to be appreciated that in some exemplary configurations,the apparatuses and methods disclosed herein may be used to emboss ordeform a single substrate layer.

The processes and apparatuses discussed herein may be used to bondvarious types of substrate configurations, some of which may be used inthe manufacture of different types of absorbent articles. To helpprovide additional context to the subsequent discussion of the processconfigurations, the following provides a general description ofabsorbent articles in the form of diapers that include components thatmay be bonded in accordance with the methods and apparatuses disclosedherein.

FIGS. 1 and 2A show an example of a diaper pant 100 that may beassembled and folded in accordance with the apparatuses and methodsdisclosed herein. In particular, FIG. 1 shows a perspective view of adiaper pant 100 in a pre-fastened configuration, and FIG. 2A shows aplan view of the diaper pant 100 with the portion of the diaper thatfaces away from a wearer oriented toward the viewer. The diaper pant 100shown in FIGS. 1 and 2A includes a chassis 102 and a ring-like elasticbelt 104. As discussed below in more detail, a first elastic belt 106and a second elastic belt 108 are connected together to form thering-like elastic belt 104.

With continued reference to FIG. 2A, the chassis 102 includes a firstwaist region 116, a second waist region 118, and a crotch region 120disposed intermediate the first and second waist regions. The firstwaist region 116 may be configured as a front waist region, and thesecond waist region 118 may be configured as back waist region. In someconfigurations, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 100. The diaper 100 may also include a laterally extending frontwaist edge 121 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100 and chassis 102 of FIG. 2A are shown with a longitudinalaxis 124 and a lateral axis 126. In some exemplary configurations, thelongitudinal axis 124 may extend through the front waist edge 121 andthrough the back waist edge 122. And the lateral axis 126 may extendthrough a first longitudinal or right side edge 128 and through amidpoint of a second longitudinal or left side edge 130 of the chassis102.

As shown in FIGS. 1 and 2A, the diaper pant 100 may include an inner,body facing surface 132, and an outer, garment facing surface 134. Thechassis 102 may include a backsheet 136 and a topsheet 138. The chassis102 may also include an absorbent assembly 140, including an absorbentcore 142, disposed between a portion of the topsheet 138 and thebacksheet 136. As discussed in more detail below, the diaper 100 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 2A, the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2A, the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100 is worn on the lower torso of a wearer, the front waist edge 121 andthe back waist edge 122 of the chassis 102 may encircle a portion of thewaist of the wearer. At the same time, the chassis side edges 128 and130 may encircle at least a portion of the legs of the wearer. And thecrotch region 120 may be generally positioned between the legs of thewearer with the absorbent core 142 extending from the front waist region116 through the crotch region 120 to the back waist region 118.

Diaper pants may be manufactured with a ring-like elastic belt 104 andprovided to consumers in a configuration wherein the front waist region116 and the back waist region 118 are connected to each other aspackaged, prior to being applied to the wearer. As such, diaper pantsmay have a continuous perimeter waist opening 110 and continuousperimeter leg openings 112 such as shown in FIG. 1.

The ring-like elastic belt 104 is defined by a first elastic belt 106connected with a second elastic belt 108. As shown in FIG. 2A, the firstelastic belt 106 defines first and second opposing end regions 106 a,106 b and a central region 106 c, and the second elastic 108 beltdefines first and second opposing end regions 108 a, 108 b and a centralregion 108 c.

The central region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region116 of the chassis 102. As shown in FIG. 1, the first end region 106 aof the first elastic belt 106 is connected with the first end region 108a of the second elastic belt 108 at first side seam 178, and the secondend region 106 b of the first elastic belt 106 is connected with thesecond end region 108 b of the second elastic belt 108 at second sideseam 180 to define the ring-like elastic belt 104 as well as the waistopening 110 and leg openings 112. The first elastic belt 106 may definean inner surface 117 a and an outer surface 119 a. The second elasticbelt 108 may define an inner surface 117 b and an outer surface 119 b.

As shown in FIGS. 2A, 3A, and 3B, the first elastic belt 106 alsodefines an outer lateral edge 107 a and an inner lateral edge 107 b, andthe second elastic belt 108 defines an outer lateral edge 109 a and aninner lateral edge 109 b. The outer lateral edges 107 a, 107 b may alsodefine the front waist edge 120 and the laterally extending back waistedge 122. The first elastic belt and the second elastic belt may alsoeach include an outer, garment facing layer 162 and an inner, wearerfacing layer 164. It is to be appreciated that the first elastic belt106 and the second elastic belt 108 may comprise the same materialsand/or may have the same structure. In some exemplary configurations,the first elastic belt 106 and the second elastic belt may comprisedifferent materials and/or may have different structures. It should alsobe appreciated that the first elastic belt 106 and the second elasticbelt 108 may be constructed from various materials. For example, thefirst and second belts may be manufactured from materials such asplastic films; apertured plastic films; woven or nonwoven webs ofnatural materials (e.g., wood or cotton fibers), synthetic fibers (e.g.,polyolefins, polyamides, polyester, polyethylene, or polypropylenefibers) or a combination of natural and/or synthetic fibers; or coatedwoven or nonwoven webs. In some exemplary configurations, the first andsecond elastic belts include a nonwoven web of synthetic fibers, and mayinclude a stretchable nonwoven. In other exemplary configurations, thefirst and second elastic belts include an inner hydrophobic,non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer layer 162 and the innerlayer 164. The belt elastic material may include one or more elasticelements such as strands, ribbons, or panels extending along the lengthsof the elastic belts. As shown in FIGS. 2A, 3A, and 3B, the belt elasticmaterial may include a plurality of elastic strands 168 which may bereferred to herein as outer, waist elastics 170 and inner, waistelastics 172. As shown in FIG. 2A, the elastic strands 168 continuouslyextend laterally between the first and second opposing end regions 106a, 106 b of the first elastic belt 106 and between the first and secondopposing end regions 108 a, 108 b of the second elastic belt 108. Insome exemplary configurations, some elastic strands 168 may beconfigured with discontinuities in areas, such as for example, where thefirst and second elastic belts 106, 108 overlap the absorbent assembly140. In some exemplary configurations, the elastic strands 168 may bedisposed at a constant interval in the longitudinal direction. In otherexemplary configurations, the elastic strands 168 may be disposed atdifferent intervals in the longitudinal direction. The belt elasticmaterial in a stretched condition may be interposed and joined betweenthe uncontracted outer layer and the uncontracted inner layer. When thebelt elastic material is relaxed, the belt elastic material returns toan unstretched condition and contracts the outer layer and the innerlayer. The belt elastic material may provide a desired variation ofcontraction force in the area of the ring-like elastic belt.

It is to be appreciated that the chassis 102 and elastic belts 106, 108may be configured in different ways other than as depicted in FIG. 2A.For example, FIG. 2B shows a plan view of a diaper pant 100 having thesame components as described above with reference to FIG. 2A, except thefirst laterally extending end edge 144 of the chassis 102 is alignedalong and coincides with the outer lateral edge 107 a of the firstelastic belt 106, and the second laterally extending end edge 146 isaligned along and coincides with the outer lateral edge 109 a of thesecond belt 108.

The apparatuses and methods according to the present disclosure may beutilized to assemble various components of pre-fastened, refastenablepant diapers 100. For example, FIG. 4 shows a schematic view of aconverting apparatus 300 adapted to manufacture pant diapers 100. Themethod of operation of the converting apparatus 300 may be describedwith reference to the various components of pant diapers 100 describedabove and shown in FIGS. 1 and 2A. Although the following methods areprovided in the context of the diaper 100 shown in FIGS. 1 and 2A, it isto be appreciated that various configurations of diaper pants can bemanufactured according to the methods disclosed herein, such as forexample, the absorbent articles disclosed in U.S. Pat. No. 7,569,039,filed on Nov. 10, 2004; U.S. Patent Publication No. 2005/0107764A1,filed on Nov. 10, 2004; U.S. patent application Ser. No. 13/221,127,filed on Aug. 30, 2011; and U.S. patent application Ser. No. 13/221,104,filed on Aug. 30, 2011.

As described in more detail below, the converting apparatus 300 shown inFIG. 4 operates to advance discrete chassis 102 along a machinedirection MD such that the lateral axis of each chassis 102 is parallelwith the machine direction, and wherein the chassis 102 are spaced apartfrom each other along the machine direction MD. Opposing waist regions116, 118 of the spaced apart chassis 102 are then connected withcontinuous lengths of advancing first and second elastic belt substrates406, 408. The chassis 102 are then folded along the lateral axis tobring the first and second elastic belt substrates 406, 408 into afacing relationship, and the first and second elastic belt substratesare connected together along regions 336, which are intermittentlyspaced along the machine direction. Each region 336 may include one ormore discrete bond sites 336 a. Then, the elastic belt substrates 406,408 are cut along the regions 336 to create discrete diapers 100, suchas shown in FIG. 1.

As shown in FIGS. 4 and 5A, a continuous length of chassis assemblies302 are advanced in a machine direction MD to a carrier apparatus 308and cut into discrete chassis 102 with knife roll 306. The continuouslength of chassis assemblies may include absorbent assemblies 140sandwiched between topsheet material 138 and backsheet material 136, legelastics, barrier leg cuffs and the like. A portion of the chassisassembly is cut-away to show a portion of the topsheet material 138 andan absorbent assembly 140.

After the discrete absorbent chassis 102 are cut by the knife roll 306,the carrier apparatus 308 rotates and advances the discrete chassis 102in the machine direction MD in the orientation shown in FIG. 5B1,wherein the longitudinal axis 124 of the chassis 102 is generallyparallel with the machine direction MD. While the chassis 102 shown inFIG. 5B1 is shown with the second laterally extending end edge 146 as aleading edge and the first laterally extending end edge 144 as thetrailing edge, it is to be appreciated that in other configurations, thechassis 102 may be advanced in other orientations. For example, thechassis may be oriented such that the second laterally extending endedge 146 is a trailing edge and the first laterally extending end edge144 is a leading edge. The carrier apparatus 308 also rotates while atthe same time changing the orientation of the advancing chassis 102. Thecarrier apparatus 308 may also change the speed at which the chassis 102advances in the machine direction MD. It is to be appreciated thatvarious forms of carrier apparatuses may be used with the methodsherein, such as for example, the carrier apparatuses disclosed in U.S.Pat. No. 7,587,966. FIG. 5B2 shows the orientation of the chassis 102 onthe carrier apparatus 308 while advancing in the machine direction. Moreparticularly, FIG. 5B2 shows the chassis 102 with the lateral axis 126of the chassis 102 generally parallel with the machine direction MD, andwherein the second longitudinal side edge 130 is the leading edge andthe first longitudinal side edge 128 is the trailing edge.

As discussed below with reference to FIGS. 3, 5C, 5D, 5E, and 5F, thechassis 102 are transferred from the carrier apparatus 308 and combinedwith advancing, continuous lengths of belt substrates 406, 408, whichare subsequently cut to form first and second elastic belts 106, 108 ondiapers 100.

With reference to FIGS. 4 and 5C, the chassis 102 are transferred fromthe carrier apparatus 308 to a nip 316 between the carrier apparatus 308and a carrier apparatus 318 where the chassis 102 is combined withcontinuous lengths of advancing front belt 406 and back belt 408substrates. The front belt substrate 406 and the back belt substrate 408each define a wearer facing surface 312 and an opposing garment facingsurface 314. The wearer facing surface 312 of the first belt substrate406 may be combined with the garment facing surface 134 of the chassis102 along the first waist region 116, and the wearer facing surface 312of the second belt substrate 408 may be combined with the garment facingsurface 134 of the chassis 102 along the second waist region 118. Asshown in FIG. 4, adhesive 320 may be intermittently applied to thewearer facing surface 312 of the first and second belt substrates 406,408 before combining with the discrete chassis 102 at the nip 316between roll 318 and the carrier apparatus 308.

With reference to FIGS. 4 and 5D, a continuous length of absorbentarticles 400 is defined by multiple discrete chassis 102 spaced fromeach other along the machine direction MD and connected with each otherby the second belt substrate 408 and the first belt substrate 406. Asshown in FIG. 4, the continuous length of absorbent articles 400advances from the nip 316 to a folding apparatus 500. At the foldingapparatus 500, each chassis 102 is folded in the cross direction CDalong a lateral axis 126 to place the first waist region 116, andspecifically, the inner, body facing surface 132 into a facing, surfaceto surface orientation with the inner, body surface 132 of the secondwaist region 118. The folding of the chassis also positions the wearerfacing surface 312 of the second belt substrate 408 extending betweeneach chassis 102 in a facing relationship with the wearer facing surface312 of the first belt substrate 406 extending between each chassis 102.Referring to FIGS. 4, 5D, and 5E, the folded discrete chassis 102connected with the first and second belt substrates 406, 408 areadvanced from the folding apparatus 500 to a bonder apparatus 334. Thebonder apparatus 334 operates to bond an overlap area 362, thus creatingdiscrete bond sites 336 a. The overlap area 362 includes a firstsubstrate layer 407 and a second substrate layer 409 shown in FIG. 5G asa portion of the second belt substrate 408 extending between eachchassis 102 and a portion of the first belt substrate 406 extendingbetween each chassis 102, respectively. The overlap area 362 may bedefined by a caliper C as shown in FIG. 5G. The caliper C is thecombined thickness of the uncompressed, unmelted first and secondsubstrates 406, 408 such as shown in FIG. 5G. Referring to FIGS. 4 and5F, a continuous length of absorbent articles are advanced from thebonder 334 to a knife roll 338 where the regions 336 are cut into alongthe cross direction to create a first side seam 178 on an absorbentarticle 100 and a second side seam 180 on a subsequently advancingabsorbent article.

Although the absorbent article is described as having a first and secondbelt substrate, it is to be appreciated that the absorbent article mayhave only one belt substrate. Further, it is to be appreciated that thechassis and belt substrate of the absorbent article may be onecontinuous substrate such that the overlap area is formed from the samesubstrate. As such, the bonder apparatus may operate to bond acontinuous substrate at an overlap area to form one or more discretebond sites.

With reference to FIG. 4, the converting apparatus may include a bonderapparatus 334. For example, FIG. 6A shows a detailed schematic side viewof a bonder apparatus 334 that may be used with the methods andapparatuses herein. As shown in FIG. 6A, the bonder apparatus 334 mayinclude a drum 364 and an anvil roll 368 located adjacent the drum 364.The anvil roll 368 includes an outer circumferential surface 370 and isadapted to rotate about an axis of rotation 372. The anvil roll 368,including the outer circumferential surface 370, may comprise acompliant material. The drum 364 may also include an outercircumferential surface 376 and is adapted to rotate about an axis ofrotation 374. The drum 364 may include one or more drum apertures 366 inthe outer circumferential surface 376. In addition, a plurality ofseaming stations 348 are positioned radially inward from the outercircumferential surface 376 and the drum apertures 366. As discussed inmore detail below, with reference to FIG. 6B, each seaming station 348may include a fluid nozzle 378 and a press member 380. Although the drum364 shown in FIG. 6A includes six seaming stations 348, it is to beappreciated that the drum 364 may be configured to include more or lessthan six seaming stations 348.

During operation, the drum 364 may rotate about the axis of rotation 374and the anvil roll 368 may rotate about the axis of rotation 372 in thedirections shown in FIG. 6A. Absorbent articles 400 may advance inmachine direction MD onto the outer circumferential surface 376, whereinthe first belt substrate 406 is between the second belt substrate 408and the outer circumferential surface 376. As the drum 364 rotates,fluid nozzles 378 of a seaming station 348 move radially outward towardthe drum aperture 366 in the outer circumferential surface 376 as shownin FIG. 6B. A fluid is heated to a temperature sufficient to at leastpartially melt the overlap area. The fluid nozzles 378 direct a jet ofthe heated fluid through the drum aperture 366 and onto an overlap areaof the first and second substrates 406, 408 to partially melts theoverlap area.

Referring to FIGS. 6A and 6B, as the drum 364 continues to rotate, thefluid nozzles 378 retract radially inward from the drum aperture 366,the drum 112 continues to rotate about the axis of rotation 374, and apress member shifts radially outward through the drum aperture 366. Theabsorbent articles 400 then pass through a nip 332 formed between thepress member 380 and the anvil roll 368 as shown in FIG. 6A. The pressmember 380 compresses the partially melted overlap area against theouter circumferential surface 370, creating one or more discrete bondsites 336 a between the first and second belt substrates 406, 408. Asthe press member 380 compresses the partially melted overlap areaagainst the outer circumferential surface 370, the press member 380 maydeform the outer circumferential surface 370 of the anvil roll 368radially inward toward the axis of rotation 372. Concurrently, theoverlap area of the first and second substrates 406, 408 is deformed ina direction Z that is non-tangential to the outer surface 425 of thepress member 380 and the outer circumferential surface 370 of the anvilroll 368, as described in more detail below. As a result, the pressmember 380 compresses the overlap area for more than an instant in timeas the absorbent articles 400 advance through the nip 332. The drum 364continues to rotate and the press member retracts radially inward fromthe drum aperture 366.

Each seaming station of the drum may include a fluid nozzle and a pressmember. FIG. 7 shows a detailed exploded view of a seaming station 348.As shown in FIG. 7, the seaming station 348 includes a base member 340that is immovably connected with and rotates with the drum. The basemember 340 is substantially square shaped and is defined by a basemember top surface 382 and a base member bottom surface 383. The basemember 340 includes a base aperture 350 extending through the basemember top and bottom surfaces 382, 383 such that a fluid nozzle 384 andpress member 380 may extend through the base aperture 350. Moreover, thebase member bottom surface 383 is immovably connected with a base link352. As discussed below, one end of the base link 352 is connected tothe base member bottom surface 383, and another end of the base link 352is operatively connected to a first shifting link 354.

With continuing reference to FIG. 7, the seaming station 348 alsoincludes a cam follower member 358 and first and second sets of camrollers 388, 390 rollingly connected with the cam follower member 358.The cam follower member 358 is substantially T-shaped, and is defined bya cam follower member first portion 360, a cam follower member secondportion 362, and a cam follower member top face 363. The cam followermember first portion 360 is operatively connected with the firstshifting link 354 and the first set of cam rollers 388 at the sameposition on the cam follower member 358. Furthermore, the second set ofcam rollers 390 is operatively connected to the cam follower membersecond portion 362 at a position radially outboard from the first set ofcam rollers 388. Also operatively connected to the cam follower member358 is a set of second shifting links 356. The set of second shiftinglinks 356 operatively connects the base member 340 to the cam followermember first portion 360 at a position relatively outboard of the secondset of cam rollers 390.

As discussed in more detail below, with reference to FIGS. 6A1 and 6B,the first and second set of cam rollers 388, 390 are configured to rollalong a stationary cam track as the drum 364 rotates. The stationary camtrack 293 surrounds the axis of rotation 374 and is defined by an innercircumferential surface 395 and a radius R that extends from the innercircumferential surface 395 of the stationary cam track 392 to the axisof rotation 374 as shown in FIG. 6A1. In some exemplary configurations,the stationary cam track 392 may include various curved and/or straightregions such that the stationary cam track 392 is defined by relativelylonger and shorter radii R at different points along the innercircumferential surface 395 of the stationary cam track 392. First andsecond sets of cam rollers 388, 390 roll on the stationary cam track 392as the drum 364 rotates. The first, second, and third shifting links354, 356, 385 pivot where the radius R of the stationary cam track 392increases or decreases as the first and second set of cam rollers 388,390 roll along the stationary cam track 392. At the same time, inregions where the stationary cam track 392 is defined by relativelylonger radii, R, the cam follower member 385 shifts radially outwardthrough the base aperture. Whereas, in regions where the stationary camtrack 392 is defined by relatively shorter radii, R, the cam followermember shifts radially inward through the base aperture. It is to beappreciated that the cam track 392 may be configured to have variousother shapes and sizes. For example, in some exemplary configurations,the cam track 392 may be configured to have a circular shape that isoffset or eccentric with respect to the axis of rotation 374. Offsettingthe stationary cam track from the axis of rotation causes the camfollower member to shift as the first and second sets of cam rollersroll along the stationary cam track.

With reference to FIGS. 7 and 8, the seaming station 348 may furtherinclude a spring member 394. The spring member 394 may be substantiallyU-shaped and defined by a spring member top face 410, a spring memberbottom face 411, and a spring member side opening 412. With reference toFIG. 7, the spring member bottom face 411 is fixedly connected to thecam follower member top face 363. The spring member 394 may extend alongthe entirety of the cam follower member top face 363. As discussed infurther detail below, the spring member side opening 412 allows thespring member 394 to flex as a press member compresses the partiallymelted overlap area against the outer circumferential surface.

The seaming station may also include a press member 380 as shown in FIG.7. The press member 380 may be substantially rectangular in shape anddefined by a press member top face 420, a press member bottom face 421,and a press member length 387. The press member 380 may includesubstantially square-shaped projections 423 extending outwardly from thepress member top face 420. The projections 423 may be defined by anouter surface 425 that is the most radially outboard surface of theprojection 423. In some exemplary configurations, the projections 423may have a flat outer surface 425 as shown in FIG. 6B. However, in otherexemplary configurations, the projections 423 may have a curved outersurface. The press member bottom face 421 is immovably connected to thespring member top face 410. The press member 380 may extend along theentirety of the spring member top face 410. As discussed in more detailbelow, the projections 423 may be arranged into two rows as shown inFIG. 7. The projections 423 may include a compliant material that mayform the outer surface 425 of the projections 423.

With continuing reference to FIG. 7, the seaming station 348 may alsoinclude heating apparatuses 384. As discussed in more detail below, eachheating apparatus 384 provides a pressurized fluid source for deliveryof heated, pressurized fluid, such as air for example, to the fluidnozzle 378. In some exemplary configurations, a valve may control egressof the fluid from the heating apparatus 384 and into a fluid nozzle 378.Each heating apparatus 384 is operatively connected to the base member340 by a set of third shifting links 385. Each third shifting link 385is operatively connected to one end of one heating apparatus 384 andalso to the cam follower member second portion 365.

With reference to FIG. 7, the seaming station may also include a fluidnozzle 378. The fluid nozzle 378 may include one or more fluid orifices424 where the heated, pressurized fluid is released from the fluidnozzle 378. Each heating apparatus 384 is immovably connected with aseparate fluid nozzle 378. As shown in FIG. 7, the fluid orifices 424may be circular and may extend in a row along the fluid nozzle 378.

Referring to FIGS. 6A and 9, the anvil roll 368 may include a compliantmaterial 342. The compliant material 342 may define the outercircumferential surface 370 of the anvil roll 368. The compliantmaterial may include, for example, silicone, natural rubber, syntheticrubber (e.g., Buna-N, Buna-S, nitrile, and neoprene), polyurethanes, ABSplastic. The compliant material may have a durometer within the Shore Ascale range of 20-100 durometer or an equivalent durometer. In someexemplary configurations, the compliant material 342 may form a sleeve343 on the anvil roll 368 as shown in FIG. 6A. The sleeve 343 may definethe outer circumferential surface 370 of the anvil roll 368. In someexemplary configurations, the anvil roll 368 may be comprised entirelyof a compliant material.

In operation, absorbent articles are advanced in the machine directionMD to a bonder apparatus 334. With reference to FIG. 6A, the absorbentarticles 400 advance in the machine direction MD onto the outercircumferential surface 376 as the drum 364 is rotating about the axisof rotation 374. The first belt substrate 406 is between the second beltsubstrate 408 and the outer circumferential surface 376. Moreparticularly, the outer layer 162 of the first belt substrate 406 may bein direct contact with the outer circumferential surface 376. And theinner layer 164 of the first belt substrate 406 may be in direct contactwith the inner layer 164 of the second belt substrate 408. The outercircumferential surface 376 is traveling at the same speed as theadvancing absorbent articles 400 such that the position the absorbentarticles 400 are received on the outer circumferential surface 376remains constant until the absorbent articles 400 are removed from thedrum 364 downstream. The overlap area of the first and second beltsubstrates 406, 408 is positioned on the outer circumferential surface376 coincident with a drum aperture 366. As discussed in more detailbelow, a seaming station 348, located radially inward from the drumaperture 366, is configured to bond a portion of the overlap area as theabsorbent articles 400 travel along the drum 364. The seaming station348 is arranged in a first configuration as the absorbent articles arereceived on the drum 364.

FIG. 10 shows a perspective view of a seaming station 348 in a firstconfiguration. With reference to FIGS. 8 and 10, in the firstconfiguration, the fluid nozzles 378 are positioned radially outwardnear the drum aperture 366 and outer circumferential surface 376, whilethe press member 380 is positioned radially inward, away from the drumaperture 366 and the outer circumferential surface 376. In addition, thefluid nozzles 378 are positioned at the same circumferential location asthe projections 423 of the press member 380, such that the heated fluidis directed to the same locations on the overlap area that willsubsequently be compressed by the press member 380.

With reference to FIGS. 6A and 6B, as the drum 364 continues to rotate,the absorbent articles 400 wrap around the outer circumferential surface376. At the same time, a jet of heated, pressurized fluid is directedfrom the heating apparatuses 384 out of the fluid nozzles 378 and ontothe overlap area of the first and second belt substrates 406, 408. Thefluid nozzles 378 are maintained a preselected distance Y from the outerlayer 162 of the first belt substrate 406 to control the pressureapplied to the overlap area by the heated fluid as shown in FIG. 6B1. Insome exemplary configurations, the distance Y between the outer layer162 of the first belt substrate 406 and the fluid nozzles 378 may bemaintained within 3 mm of the preselected distance Y.

A position control apparatus may be used to maintain the absorbentarticles within a constant distance from the outer circumferentialsurface of the drum as the fluid is heating the overlap area. In someexemplary configurations, the position control apparatus 450 may be abelt apparatus 451 as shown in FIG. 11. The position control apparatus450 may be located adjacent the drum 364 and may take the shape of atleast a portion of the outer circumferential surface 376. The positioncontrol apparatus may hold the absorbent articles 400 in the range of 0millimeters to about 10 millimeters from the outer circumferentialsurface of the drum, or between about 0.5 millimeters to about 5millimeters from the outer circumferential surface.

Once the overlap area is at least partially melted, and as the drum 364continues to rotate, the seaming station shifts to a secondconfiguration. With reference to FIGS. 6A, 6A1, 6B, and 6B1, the firstand second sets of cam rollers 388, 390 roll on the stationary cam track392 as the drum 364 rotates. The stationary cam track 392 remainsstationary while the first and second set of cam rollers 388, 390 rollalong the stationary cam track 392. As the first and second sets of camrollers 388, 390 roll from regions where the radius R of the stationarycam track 392 is defined by relatively shorter radii R to regions wherethe radius R of the stationary cam track 392 is defined by relativelylonger radii R, the first, second, and third shifting links 354, 356,385 pivot. With reference to FIG. 6B, the first shifting link 354 pivotsat the base link 352 and at the cam follower member 358, while the setof second shifting links 356 pivot at the cam follower member 358 and atthe base member 340. At the same time, the cam follower member 358shifts radially outward toward the outer circumferential surface 376.The third shifting links 385 also pivot at the cam follower member 358,causing the heating apparatuses 384 to move radially inward, away fromthe outer circumferential surface 376, and causing the fluid nozzles 378to spread circumferentially apart from each other on either side of thepress member 380. The seaming station 348 continues to shift until thefirst and second set of cam rollers 388, 390 roll along regions of thestationary cam track 392 where the radius R of the stationary cam track392 remains constant, which corresponds to the second configuration ofthe seaming station 348. The seaming station 348 remains in the secondconfiguration until the first and second set of cam rollers 388, 390travel along the stationary cam track 392 to regions where thestationary cam track is defined by relatively shorter radii.

FIG. 12 shows a perspective view of a seaming station 348 in the secondconfiguration. With reference to FIG. 12, at the second configuration,the press member 380 is extending through the drum aperture beyond theouter circumferential surface, the heating apparatuses 384 arepositioned radially inward, away from the drum aperture 366, and thefluid nozzles 378 are located on either side of the cam follower memberadjacent to the outer circumferential surface 366.

With reference to FIGS. 6A and 6B, while the drum 364 continues torotate and the seaming station 348 is in the second configuration, thepartially melted overlap area approaches the anvil roll 368 locatedadjacent the drum 364. As the absorbent articles 400 advances throughthe nip 332 formed between the anvil roll 368 and drum 364, the pressmember 380, which is extending radially outward from the drum aperture366, compresses the partially melted overlap area against the outercircumferential surface 370. As shown in FIGS. 9 and 13-15, as theabsorbent articles 400 advance through the nip 332 between the rotatinganvil roll 368 and the press member 380 of the seaming station 348, theprojections 423 of the press member 380 deform the outer circumferentialsurface 370 of the anvil roll 368 radially inward toward the axis ofrotation 372. As a result, the first and second substrates 406, 408deform in a direction, Z, that is non-tangential to the outercircumferential surface 370 of the anvil 368 and the outer surface 425of the projections 423 of the press member 380.

The anvil roll 368 may be configured to deform in a direction toward theaxis of rotation 372 by a radial thickness R_(T) that is at least 25% ofthe caliper, C, of the combined, uncompressed and unmelted first andsecond substrates 406, 408. In some exemplary configurations, the anvilroll 368 may deform by a radial thickness R_(T) that is at least 30%, atleast 40%, at least 50%, at least 60%, at least 70%, at least 80% of thecaliper, C, of the combined, uncompressed and unmelted first and secondsubstrates 406, 408.

The projections 423 of the press member 380 are configured to contactthe same locations of the overlap area that were at least partiallymelted by the heated fluid as shown in FIG. 6B, thus forming discretebond sites 336 a in the overlap area. The spring member 394 may be usedto apply a predetermined force to the overlap area between the pressmember 380 and the anvil roll 368. Once compressed, the absorbentarticles advance off of the drum outer circumferential. The drumcontinues to rotate and the seaming station shifts back to the firstconfiguration in order to form discrete bond sites in a subsequentabsorbent article.

In some exemplary configurations, the distance from the absorbentarticles to the fluid nozzles may range from 0 millimeters to about 20millimeters, or between about 0 millimeters and about 5 millimeters forexample, or between about 0.5 millimeters and about 3 millimeters.Control of the distance between the first and second substrate and thefluid orifice 424 may also result in a relatively more predictable fluidspray and melt pattern during the heating process.

The heated fluid may include ambient air or other gases. It is to beappreciated that the fluid may be heated to various temperatures andpressurized to various pressures. For example, in some exemplaryconfigurations, the fluid may be heated up to a temperature ranging fromthe lower melting point of first and second belt substrates minus 30° C.to the lower melting point of the first and second belt substrates plus100° C. In some exemplary configurations, the fluid pressure may rangefrom 0.1×10⁵ Newtons per square meter to 1×10⁶ Newtons per square meter.In some exemplary configurations, the heated fluid may be directedtoward at least one of the first and second belt substrates for a timeinterval ranging from 10 to 1000 milliseconds or greater. Shorter orgreater time intervals may be used.

In some exemplary configurations, the press member may compress thepartially melted overlap area against the outer circumferential surfaceat a pressure in the range of about 1×10⁵ Newtons per square meter toabout 1×10⁸ Newtons per square meter. In some exemplary configurations,the press member 366 may compress the first and second belt substratesfor a time period ranging from 10 to 1000 milliseconds or greater.Shorter or greater time intervals may be used.

Referring to FIG. 10, it is to be appreciated that the projections 423may be regularly or irregularly spaced in various configurations and maybe oriented in various directions. The projections 423 may have acircular, oval, or various other shapes. In some exemplaryconfigurations, the projections of the press member may have a smoothsurface such that the discrete bond sites will be flat. However, in someexemplary configurations, the projections of the press member may have arough surface such that the discrete bond sites will have a texture.With reference to FIG. 10, the projections 423 may have a height 440 inthe range of about 0.5 millimeters to about 5 millimeters. In someexemplary configurations, the projections may have a width 442 in therange of about 2 millimeters to about 10 millimeters, or between about 4millimeters to about 6 millimeters.

While it is shown in FIGS. 8 and 12 that the spring member 390 has aU-shape, it is to be appreciated that various other spring members maybe used to absorb pressure from the press member 380 compressing theoverlap area between the outer circumferential surface. By controllingthe amount of force applied to the overlap area, it is possible to applya force sufficient to form discrete bond sites to minimize damage to thesubstrates and/or forming relatively weak discrete bonds.

The temperature and pressure of the fluid are maintained within aspecified range once the nominal set points are selected. For example, aset point may be selected from the ranges discussed above, and thetemperature may then be maintained in a fixed range around the nominalset point, such as ±30° C., and the pressure may be maintained in afixed range around the nominal set point, such as ±1 bar. The acceptablerange will depend on the relationship between the properties, such assoftening point and/or melting temperature, of the materials to bejoined and the nominal set point selected. For example, a nominal setpoint above the melting temperature of one or more of the materials tobe joined may require a tighter control range than a nominal set pointwell below the melting temperature of one or more material to be joined.The control range may be asymmetrical about the nominal set point. Bysufficiently heating, it is meant that the fluid is heated to atemperature that will enable at least partial melting, or at leastsoftening, of the substrate or substrates. Sufficient heating may varywith the materials and equipment used. For example, if the heated fluidis applied to the substrate or substrates almost immediately, withlittle or no time to cool, the fluid may be heated to approximately thesoftening point or approximately the melting point of the substrate orsubstrates. If the heated fluid is directed to the substrate orsubstrates over some gap in time or distance, such that the heated fluidmay cool somewhat before interacting with the substrate or substrates,it may be necessary to heat the fluid above, possibly significantlyabove, the softening point or melting point of the substrate orsubstrates.

The duration of energy transfer in the process described herein may be adynamic process, and may create a temperature gradient across themeltable components' cross sections. That is, the core of the meltablecomponents may remain solid while the exterior surface of the meltablecomponents melt or come close to melting. Even below the meltingtemperature, the exterior surface may reach a softening point, such thatplastic deformation of the material may occur at a much lower load thanfor the same material at ambient temperature. Thus, if one or more ofthe materials to be joined have a softening point, the process may beadjusted to achieve a temperature in at least a portion of first andsecond belt substrates 406, 408 between the softening point and themelting point. The use of a temperature at or above the softening pointbut below the melting point of one or more of the meltable componentsmay allow for the creation of a strong bond between first and secondbelt substrates 406, 408 with reduced disruption to the structure of themeltable components e.g., attenuating or otherwise weakening themeltable components.

With reference to FIGS. 4 and 5F, once the discrete bond sites 336 a areformed, the absorbent articles 400 advance in the machine direction MDto a knife roll 338 where the regions 336 are cut into along the crossdirection to create a first side seam 178 on an absorbent article 100and a second side seam 180 on a subsequently advancing absorbentarticle. In some exemplary configurations, it is to be appreciated thatthe knife roll may be integral with the press member such that as thepress member compresses the overlap area, the press member also cuts theoverlap area.

In some exemplary configurations, a press member 580 may be in the formof a rotary drum 520. As shown in FIG. 16, the rotary drum 520 may havean outer circumferential surface 522 and a plurality of projections 523extending radially outward from the outer circumferential surface 522 ofthe rotary drum 520. In such an exemplary configuration, an anvil roll568 having an outer circumferential surface 570 may be located adjacentto the rotary drum 520, forming a nip 532 there between. The anvil roll568 may comprise a compliant material. In other exemplaryconfigurations, an anvil roll 668 may have a plurality of apertures 534in an outer circumferential surface 670 such as shown in FIG. 17. Theapertures 534 may be configured to mate with the projections 523 of therotary drum 520. In some exemplary configurations, the anvil roll 668shown in FIG. 17 may be made of a rigid material, such as metal.

In yet other exemplary configurations, the press member 780 may be inthe form of a first conveyor 720 as shown in FIG. 18. The first conveyor720 may have an outer surface 722 and a plurality of projections 723extending outward from the outer surface 722 of the first conveyor 720.An anvil roll 730 may be configured as a second conveyor 740 may belocated adjacent to the first conveyor 720, forming a nip 732 therebetween. The second conveyor 740 may have an outer surface 742. Thesecond conveyor 740 may comprise a compliant material. In otherexemplary configurations, a second conveyor 840 may have a plurality ofapertures 834 in an outer surface 842 such as shown in FIG. 19. Theapertures 736 of the second conveyor 840 may be configured to mate withthe projections 723 of the first conveyor 720. In some exemplaryconfigurations, the second conveyor 840 shown in FIG. 19 may be made ofa rigid material, such as metal.

It is to be appreciated that the methods and apparatuses disclosedherein may be used with various seaming apparatuses. For example, themethods and apparatuses disclosed herein may be used with U.S. patentapplication Ser. No. 13/401,907, filed Feb. 22, 2012 and U.S. patentapplication Ser. No. 13/402,056, filed Feb. 22, 2012.

Although the bonder apparatus is described in the context of bondingbelts to make side seams, it is to be appreciated that the methods andapparatuses herein can be used to bond various components and substratestogether. The apparatuses and methods for bonding substrates disclosedherein can also be configured to operate in accordance with theapparatus and methods disclosed in U.S. Pat. No. 6,248,195 and U.S.Patent Application Publication No. 2012-0021186, filed Jun. 7, 2010.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An apparatus for bonding first and secondsubstrates together, wherein the first and second substrates having acombined, uncompressed caliper, the apparatus comprising: a drumcomprising an outer circumferential surface and a drum aperture in theouter circumferential surface, wherein the drum is adapted to rotateabout an axis of rotation; a fluid nozzle moveably connected to thedrum, located radially inward relative to the drum aperture, and adaptedto direct a fluid radially outward through the drum aperture; an anvilroll comprising an outer circumferential surface located adjacent thedrum so as to define a nip between the anvil roll and the drum, theanvil roll adapted to rotate about an axis of rotation, the anvil rollcomprising a compliant sleeve that defines the outer circumferentialsurface of the anvil roll, wherein the outer circumferential surface ofthe anvil roll is deformable toward the axis of rotation of the anvilroll; and a press member moveably connected to the drum, locatedradially inward relative to the drum aperture, and adapted to extendthrough the drum aperture.
 2. The apparatus of claim 1, wherein theanvil roll is configured to deform by a radial thickness that is atleast about 25% of the combined, uncompressed caliper of the first andsecond substrates.
 3. The apparatus of claim 1, wherein the sleeve isconfigured to deform by a radial thickness that is at least 50% of thecombined, uncompressed caliper of the first and second substrates. 4.The apparatus of claim 1, wherein the compliant outer circumferentialsurface of the anvil roll has a shore A durometer of about 20 to about100.
 5. The apparatus of claim 1, wherein the press member comprises aprojection extending radially outward relative to the axis of rotation,wherein the projection defines an outer surface.
 6. The apparatus ofclaim 5, wherein the press member and the anvil roll are configured todeform the first and second substrates in a direction that isnon-tangential to the outer surface of the projection.
 7. The apparatusof claim 1, wherein the press member comprises a plurality ofprojections, the projections having an outer surface.
 8. The apparatusof claim 7, wherein the outer surface of the projections is rounded. 9.The apparatus of claim 7, wherein the projections are spaced apart fromeach other projection.
 10. The apparatus of claim 1, wherein the fluidis ambient air.
 11. An apparatus for bonding first and second substratestogether, wherein the first and second substrates having a combined,uncompressed caliper, the apparatus comprising: a drum comprising anouter circumferential surface and a drum aperture in the outercircumferential surface, wherein the drum is adapted to rotate about anaxis of rotation; a fluid nozzle moveably connected to the drum, locatedradially inward relative to the drum aperture, and adapted to direct afluid radially outward through the drum aperture; an anvil rollcomprising an outer circumferential surface located adjacent the drum soas to define a nip between the anvil roll and the drum, the anvil rolladapted to rotate about an axis of rotation; and a press member moveablyconnected to the drum, located radially inward relative to the drumaperture, and adapted to extend through the drum aperture.
 12. Theapparatus of claim 11, wherein the anvil roll comprising a compliantsleeve that defines the outer circumferential surface of the anvil roll,wherein the outer circumferential surface of the anvil roll isdeformable toward the axis of rotation of the anvil roll.
 13. Theapparatus of claim 12, wherein the anvil roll is configured to deform bya radial thickness that is at least about 25% of the combined,uncompressed caliper of the first and second substrates.
 14. Theapparatus of claim 12, wherein the sleeve is configured to deform by aradial thickness that is at least 50% of the combined, uncompressedcaliper of the first and second substrates.
 15. An apparatus for bondingfirst and second substrates together, wherein the first and secondsubstrates having a combined, uncompressed caliper, the apparatuscomprising: a drum comprising an outer circumferential surface and adrum aperture in the outer circumferential surface, wherein the drum isadapted to rotate about an axis of rotation; a fluid nozzle moveablyconnected to the drum, located radially inward relative to the drumaperture, and adapted to direct a fluid radially outward through thedrum aperture; and a press member moveably connected to the drum,located radially inward relative to the drum aperture, and adapted toextend through the drum aperture.
 16. The apparatus of claim 15,comprising an anvil roll comprising an outer circumferential surfacelocated adjacent the drum so as to define a nip between the anvil rolland the drum, the anvil roll adapted to rotate about an axis ofrotation, the anvil roll comprising a compliant sleeve that defines theouter circumferential surface of the anvil roll, wherein the outercircumferential surface of the anvil roll is deformable toward the axisof rotation of the anvil roll.
 17. The apparatus of claim 16, whereinthe press member compresses the first and second substrate layersbetween the anvil roll at a pressure of about 1×10⁵ Newtons per squaremeter to about 1×10⁸ Newtons per square meter.
 18. The apparatus ofclaim 1, wherein the fluid is heated to a temperature sufficient to atleast partially melt the first and second substrate layers.
 19. Theapparatus of claim 16, wherein the compliant outer circumferentialsurface of the anvil roll has a shore A durometer of about 20 to about100.
 20. The apparatus of claim 15, wherein the press member comprises aplurality of projections, the projections having an outer surface.